KYMCO MXU 500i Manual Download

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5-8

POTENTIAL HAZARD

Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire and severe injury. Fuel

expands when it heats up. If the fuel tank is overfilled, fuel

could spill out due to heat from the engine.

HOW TO AVOID THE HAZARD

Do not overfill the fuel tank. Be careful not to spill fuel,

especially on the engine or exhaust pipe. Wipe up any spilled

fuel immediately. Be sure the fuel tank cap is closed securely.

Do not refuel right after the engine has been running and is still

very hot.

5.4. DRIVE SHAFT BOOTS

Check the rubber drive shaft boots for damage or leaking

grease. If necessary, have your KYMCO dealer replace them.

(1) Drive shaft boots

Summary of Contents for MXU 500i

Page 1: ...3 4 ENGINE SERIAL NUMBER 3 3 3 5 PARTS LOCATIONS 3 4 4 CONTROL FUNCTIONS 4 1 4 1 IGNITION SWITCH 4 1 4 2 INSTRUMENTS AND INDICATOR 4 2 4 3 LEFT HANDLEBAR SWITCHES 4 15 4 4 Winch switch 4 18 4 5 EPS AB...

Page 2: ...S 5 11 5 12 BATTERY CUT OFF SWITCH 5 11 5 13 TIRES 5 12 5 14 HOW TO MEASURE TIRE PRESSURE 5 13 5 15 TIRE WEAR LIMIT 5 14 5 16 COOLANT 5 14 6 OPERATION 6 1 6 1 STARTING A COLD ENGINE 6 1 6 2 STARTING A...

Page 3: ...OL KIT TOOL KIT COMPARTMENT 8 2 8 2 PERIODIC MAINTENANCE LUBRICATION 8 4 8 3 ENGINE OIL 8 7 8 4 REAR GEAR BOX OIL 8 14 8 5 FRONT GEAR BOX OIL 8 16 8 6 SPARK PLUG INSPECTION 8 18 8 7 SPARK ARRESTER 8 1...

Page 4: ...T 8 39 8 23 DRIVE SHAFT BOOTS 8 39 8 24 CABLE INSPECTION AND LUBRICATION 8 40 8 25 TROUBLESHOOTING 8 41 9 CLEANING AND STORAGE 9 1 9 1 CLEANING YOUR ATV 9 1 9 2 STORAGE 9 5 9 3 SPECIFICATIONS 9 7 9 4...

Page 5: ...est service possible PROTECT YOUR SPORT Being able to use and enjoy your ATV requires you and your family to operate it in a responsible manner Before riding your ATV you should Learn and adhere to al...

Page 6: ...UAL CAREFULLY Your owner s manual contains important information on safety operation and maintenance Anyone who operates this ATV should carefully read and understand the contents of this manual befor...

Page 7: ...eans ATTENTION BE ALERT YOUR SAFETY CAN BE AFFECTED Failure to follow instructions associated with a WARNING symbol could result in severe injury or death to the operator a passenger a bystander or a...

Page 8: ...ormation about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenanc...

Page 9: ...tand this information before riding They contain important information for safe and proper operation of your ATV The labels should be considered as permanent parts of the vehicle If a label comes off...

Page 10: ...1 2 1 1 LABELS FOR T3b MODELS FOR PASSENGER SEAT ONLY...

Page 11: ...1 3 MXU700i MXU550i...

Page 12: ...1 4...

Page 13: ...1 5...

Page 14: ...e an ATV without proper training or instruction Beginners should receive training from a certified instructor Always follow the age recommendation A child under 16 years old should never operate an AT...

Page 15: ...lways follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Alway...

Page 16: ...to lean sharply to one side Go straight down the slope where possible Never attempt to turn the ATV around on any slope until you have mastered the turning technique described in this manual on level...

Page 17: ...t friction dry out the linings Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper install...

Page 18: ...gnition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise...

Page 19: ...unning the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your machine in...

Page 20: ...ion Switch Right Storage open and lock 3 2 IDENTIFICATION NUMBER RECORDS Record the keys identification number frame serial number and engine serial number information for assistance when order replac...

Page 21: ...3 2 3 3 ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase Engine Serial Number...

Page 22: ...3 3 3 4 FRAME NUMBER The frame number is stamped on the right side of vehicle...

Page 23: ...ly from your vehicle 01 Rearview mirrors 02 Position lights 03 High beam head light 04 Low beam headlight 05 Right turn signal light 06 Winch 07 Left turn signal light SOME MODELS ONLY NOTE The figure...

Page 24: ...11 Central storage compartment 12 Tool storage 13 Taillights Brake lights 14 Right rear turn signal light 15 Spark arrester 16 Trailer hitch 17 License light 18 Trailer socket SOME MODELS ONLY NOTE Th...

Page 25: ...ck 20 Battery Fuse Reservoir water tank 21 Rider Seat 22 Passenger Seat 23 Exhaust system 24 Rear cargo rack 25 Left foot peg SOME MODELS ONLY NOTE The figures of machine you purchased may differ slig...

Page 26: ...cap 29 Accessory socket 30 Battery cut off switch 31 Brake pedal fluid reservoir 32 Right foot peg 33 Oil level inspection window 34 Rear brake pedal SOME MODELS ONLY NOTE The figures of machine you...

Page 27: ...adlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch 38 Rear parking brake lever 39 Ignition switch 40 2WD 4WD select switch and differential lock 41 Throttle Lever 42 Fro...

Page 28: ...ective switch positions are as follows OFF All electrical circuits are switched off except hazard light The key can be removed in this position ON All electrical circuits are switched on The engine ca...

Page 29: ...e Level Warning Indicator 1 Mode Button This button is used to switch km h mph km and mile This button is also used to adjust the time and reset the trip of meter 2 Engine Tachometer The electronic ta...

Page 30: ...I system has fails 6 Neutral Gear Position Indicator The indicator light up when gear shifts to neutral gear position 7 Multi Function Display The display includes the following functions Digital cloc...

Page 31: ...n during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes 12 Brake Level Warning Indicator When the indicator light is on Check if the fl...

Page 32: ...age 6 Fuel Gauge 7 Odometer Tripmeters Engine Running Time OPC 4 2 2 Change Units On ODO mode press and hold MODE button for more than 2 seconds to switch units The speed unit and mileage unit will be...

Page 33: ...Turn the ignition switch ON b Press ADJ button to select ODO mode NOTE Digital clock can be adjusted in ODO mode only never select TRIP when you want to adjust your digital clock c Press and hold both...

Page 34: ...4 7 d To set the hour press the ADJ button until the desired hour e Press the MODE button the minute display will start flashing...

Page 35: ...4 8 f To set minute press the ADJ button until the desired minute g To end the adjustment Press and hold the MODE button and ADJ button in the same time until the digital clock stop flashing...

Page 36: ...drive mode is in the 2WD Shows the drive mode isn t in the 4WD Differential lock indicator The front axle is equipped with a lockable differential that allows the operator to choose between an open d...

Page 37: ...4 10 3 Gear Select Display Display the current gear position 4 Speedometer Display the riding speed in km h or mph 5 Battery Voltage Display the current battery voltage...

Page 38: ...graduated display The normal operating fuel range is with the section between the segment F and segment E a Fuel indicator b Segment F c Segment E The fuel indicator and the last square start flashing...

Page 39: ...hows the trip distance in Km or in mile There is tripmeters Press ADJ button to select ODO TRIP A TRIP B and Engine Running Time 0 1 6mins 1 1hr a Change Unit To change the unit on ODO mode press and...

Page 40: ...4 13 b Reset Tripmeter Press ADJ select tripmeter Press and hold both the MODE button and ADJ button in the same time until the tripmeter is reset...

Page 41: ...alarm signal and OPC appears on the gauge display when the any of following conditions is fulfilled Ignition is switched on or the engine is running below the 1800 rpm Thumb throttle is not actuated N...

Page 42: ...to another lane The turn signal light will flash when the switch is operated and ignition switch is ON For turning to the left For turning to the right The instrument turn signal indicator light will...

Page 43: ...rn on this switch when parking or there is a special condition After the hazard switch is turned on it will not reset automatically Be sure to reset it after use to avoid affecting the traffic safety...

Page 44: ...gine stop switch is used to stop the engine in an emergency such as engine overturns or when the throttle cable is stuck If your ATV is stopped with the ignition switch ON and the engine stop switch O...

Page 45: ...g the switch in starts the engine See starting instructions prior to starting engine 4 4 Winch switch To control cable in and out To determine the Cable OUT trigger to the OUT position To determine th...

Page 46: ...ABS MODELS ONLY ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight The ABS automatically regulates brake force Intermittently gaining gr...

Page 47: ...e has one 4 Don t let the other end touch metal It to the positive terminal of the good battery Connect Use a remote positive terminal if the vehicle has one 5 Now connect the black negative cable to...

Page 48: ...r To select the drive mode push the button to switch to the desired position To check your present drive mode look at the multifunction display 4 6 2 Differential Lock Switch The Differential lock swi...

Page 49: ...ver POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVO...

Page 50: ...ed of the ATV 1 Adjuster 2 Locknut 3 13mm 0 52in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation...

Page 51: ...by squeezing the front brake lever 4 9 2 Rear Brake Lever The rear brake is operated by squeezing the rear brake lever near left handgrip 1 Rear brake lever 2 Front brake lever 4 9 3 BRAKE PEDAL This...

Page 52: ...er until the lock lever releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position 1 Lock lever 4 10 2 Rear parking brake To set the rear parking brake...

Page 53: ...sing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before start...

Page 54: ...rive select lever is used to shift your ATV into the low high neutral reverse and park positions Refer to CH 5 1 1 for drive select lever adjustment and operation L Low R Reverse H High P Park N Neutr...

Page 55: ...art acceleration Intake air leak Fuel contaminated deteriorated Pinched or clogged fuel hose Faulty fuel pump Engine stall hard to start rough idling Intake air leak Fuel contaminated deteriorated Pin...

Page 56: ...evice and then clean off any abrasive particles The plug may also be to other suitable tool If the insulator is cracked replace the plug Use the standard plug 4 15 BATTERY INSPECTION Checking the batt...

Page 57: ...align the tabs on the seat with the grommets on the frame and press the seat down until it locks 4 16 3 PASSENGER SEAT EPS MODELS ONLY To remove the seat pull the passenger seat lock lever upward and...

Page 58: ...as Check local regulations before riding 1 Flag pole bracket 4 18 TRAILER HITCH SOME MODELS ONLY The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball a...

Page 59: ...t 3 Right storage compartment 4 19 1 Cup Holder Cup holder is provided at the left side Some plastic bottle may not fit into the cup holder depending on their size and shape NOTE Never ride with any o...

Page 60: ...should be stored in the plastic bag before store in the storage compartment Be careful not to flood this area when washing your ATV NOTE Do not put valuables inside the storage compartments 4 19 3 Ri...

Page 61: ...ot to flood this accessory socket when washing your ATV To use the accessory socket 1 Turn the ignition switch ON and then start the engine 2 Turn the headlights OFF 3 Open the accessory socket cap 2...

Page 62: ...ted at the rear side of the vehicle It is only allowed to provide vehicle lighting on the trailer 4 21 1 Socket Wiring Function Color 1 Brake Light G Y 2 LH Turn O 3 Fog Light Signal L 1 4 LH Indicato...

Page 63: ...ry CH 5 3 ENGINE OIL FINAL GEAR DIFFERENTIAL GEAR OIL Check oil level Fill with oil if necessary Check for leakage CH 5 5 CH 5 6 CH 5 7 DRIVE SHAFT BOOTS Check for damage CH 5 4 THROTTLE Check for pro...

Page 64: ...ures and schedules described in the Owner s Manual 5 1 DRIVE SELECT LEVER Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the s...

Page 65: ...ting with improperly adjusted drive select lever WHAT CAN HAPPEN You may lose control of the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N po...

Page 66: ...neutral and turn the ignition switch OFF and wait the engine cools down 2 Remove the seat 3 Remove the front cover 4 Remove five fasteners and then remove the central storage compartment cover and gea...

Page 67: ...Verify the length of the shift rod is 341 5mm 0 5mm To adjust the length by loosening the lock nuts 1 and rotating the shift rod 2 until you achieve the proper length 150mm then tighten both locknuts...

Page 68: ...to make sure they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You...

Page 69: ...esigned to use regular unleaded gasoline with a pump octane number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium...

Page 70: ...W TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed secur...

Page 71: ...Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance ENGINE OIL QUANTITY Periodic oil change 3 0L 2 64 lm...

Page 72: ...TITY Periodic oil change 0 23 L 0 20 Imp qt 0 243 US qt Total amount 0 25 L 0 22 Imp qt 0 265 US qt 5 7 FRONT GEAR CASE OIL Make sure the front gear case oil at the specified level Add oil as necessar...

Page 73: ...torque 5 10 LIGHTS Check the headlight and taillight to make sure they are in working condition Repair as necessary for proper operation 5 11 SWITCHES Check the operation of the headlight switch engin...

Page 74: ...AT25x10 12 Tubeless EPS Front AT26x8 14 Tubeless EPS Rear AT26x10 14 Tubeless 2 The tires should be set to the recommended pressure Recommended tire pressure Front 34 41 kpa 0 35 0 41 kgf cm 2 5 1 5 9...

Page 75: ...m2 5 5 psi Rear 0 35kgf cm2 5 0 psi 0 32kgf cm2 4 7 psi 0 35kgf cm2 5 0 psi 5 14 HOW TO MEASURE TIRE PRESSURE Use the low pressure tire gauge Tool kit NOTE The low pressure tire gauge is included as s...

Page 76: ...servoir tank when the engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if it is between the FULL and LOW marks on the tank If the coolant level is a...

Page 77: ...WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over th...

Page 78: ...nual carefully If there is a control or function you do not understand ask your KYMCO dealer 6 1 STARTING A COLD ENGINE POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You cou...

Page 79: ...t ambient temperature below 18 C 0 F NOTE The engine can be started in any gear if the brake lever is applied However it is recommended to shift into neutral or park before starting the engine When th...

Page 80: ...ction system do not remove or install a battery wire when the ignition switch is at the ON position NOTE Do not allow water enter the right case See the engine break in section prior to operating engi...

Page 81: ...e transmission may be damaged NOTE Apply the rear brake and shift the shift lever into P position before turning off the engine when parking the vehicle on an incline if you park on an incline with sh...

Page 82: ...light should be on If the light does not come on ask a KYMCO dealer to inspect the machine 4 Check behind for people or obstacles and then release the rear brake pedal 5 Open the throttle lever gradua...

Page 83: ...ottle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine c...

Page 84: ...pply the parking brake The front brake lever has three locked position that allow it to be used as a parking brake To set the front parking brake see CH 1 Locked position 2 Certainly locked position 3...

Page 85: ...s If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on...

Page 86: ...se a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding c...

Page 87: ...lbs Trailer Maximum towing capacity 150 kg 330 lbs Tongue weight 16kg 35 lbs 1 Front cargo rack 2 Rear cargo rack 6 7 2 One Rider with Passenger As originally equipped this ATV can carry cargo or tow...

Page 88: ...carry the slower you should go Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain care...

Page 89: ...7 1 7 RIDING YOUR ATV...

Page 90: ...s acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity provi...

Page 91: ...more difficult maneuvers POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the AT...

Page 92: ...hild under 16 should never operate an ATV with engine size greater than 90cc 7 4 NEVER CARRY PASSENGER ON THE CARGO RACKS POTENTIAL HAZARD Carrying a passenger on the cargo racks WHAT CAN HAPPEN Great...

Page 93: ...the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing incr...

Page 94: ...l or drugs POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and...

Page 95: ...s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Operating this ATV with improper tires or with impr...

Page 96: ...in an accident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience 7 8 1 Speed limiter For riders inexperienced with thi...

Page 97: ...senger Maximum load Front cargo rack 52 kg 114 6 lbs Rear cargo rack 95 kg 209 5 lbs 7 9 4 Loading and operational guidelines Carrying cargo will affect how your ATV handles and greatly reduce its abi...

Page 98: ...KYMCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and u...

Page 99: ...ll parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction If you have quest...

Page 100: ...rds during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a foot peg your foot or leg may come int...

Page 101: ...of the machine or overturn POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt s...

Page 102: ...rk the machine in a place where pedestrians or children are not likely to touch it POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation cou...

Page 103: ...pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position and shift the d...

Page 104: ...corner or turn close the throttle fully and slow the ATV down by applying both front and rear brakes at the same time POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control ca...

Page 105: ...e you to lose control POTENTIAL HAZARD Operating on excessively steep slopes WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep slopes than on level surfaces or small slopes HOW T...

Page 106: ...bing slopes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopes with excessively slippery or loose surfaces Shift your weight forwar...

Page 107: ...cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any slope until you have mastered the turning technique as described in the Owner s M...

Page 108: ...ou are in 2WD apply only the front brake When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will...

Page 109: ...position P after you are stopped 4 Lock parking brake If you begin rolling backwards Keep weight up slope 2WD Never apply the rear brake while rolling backwards Apply the front brake 4WD Apply both fr...

Page 110: ...front brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the slope using the front brake lever to control sp...

Page 111: ...scending a slope with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all...

Page 112: ...se loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down slopes as described in this Owner s Manual Note a special technique is required w...

Page 113: ...If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position y...

Page 114: ...pection adjustment and lubrication are explained on the following pages POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body ca...

Page 115: ...rm routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer The tool kit includes the following items 1 Tool bag 2 10 14...

Page 116: ...ch in some situation could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should...

Page 117: ...ck oil level oil leakage Replace every 12 months Differential gear oil Check oil level oil leakage Replace every 12 months Air filter element for engine and V belt compartment Clean More often in wet...

Page 118: ...rake Check operation and brake fluid Replace brake pad if necessary Coolant Check coolant leakage Replace if necessary V belt Check operation Replace if damage or excessive wear Exhaust system Check l...

Page 119: ...haft boots Check operation Replace if damaged Suspension Check operation Correct if necessary Brake Check operation and brake fluid Replace brake pad if necessary Knuckle shafts Steering shaft Lubrica...

Page 120: ...m up the engine for several minutes and stop it C Check the oil level through the inspection window D The oil level should be between the maximum H and minimum L marks If the level is low add oil to r...

Page 121: ...e for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and oil filter cap 2 to drain the oil Be sure no foreign material enters the crankcase When removing...

Page 122: ...oil and install the oil fill cap Recommended oil see CH 9 3 ENGINE OIL QUANTITY 550 700 Periodic oil change 3 0L 2 64 lmp qt 3 18 US qt 2 4 L 2 11 Imp qt 2 54 US qt After draining and oil filter cart...

Page 123: ...replacement A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and drain plug washer 2 to drain...

Page 124: ...oil filter cartridge is not being replaced E Remove the two fasteners and then remove front cover F Remove the four fasteners and then remove the central storage cover G Remove the five fasteners and...

Page 125: ...4 of the new oil filter cartridge NOTE An oil cartridge wrench is available at a nearby KYMCO dealer NOTE Make sure the O ring is seated properly J Install the new oil filter cartridge with an oil ca...

Page 126: ...then install the engine oil filler cap and tighten it Recommended oil see CH 9 3 Oil quantity see CH 9 3 Be sure no foreign material enters the crankcase N Start the engine and warm it up for several...

Page 127: ...e complete and rapid draining Rear gear box oil replacement To drain the oil first place an oil drain pan under the oil drain plug 1 1 Oil drain plug 2 Oil filler cap 3 Oil level check bolt washer 1 R...

Page 128: ...4 Remove the oil level check bolt washer 3 Make sure the oil level reaches the oil level check hole 5 Install the oil filler cap and oil level check bolt Tightening Torque Oil filler cap 14 7 N m 1 5...

Page 129: ...sure complete and rapid draining Front gear box oil replacement 1 To drain the oil first place an oil drain pan under the oil drain plug washer 1 2 Remove the oil filler bolt 2 1 Oil drain plug washer...

Page 130: ...qt 0 265 US qt 6 Remove the oil level check bolt washer Make sure the oil level reaches the oil level check hole 7 Install the oil filler cap and oil level check bolt Tightening Torque Oil filler cap...

Page 131: ...and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the p...

Page 132: ...ESTER T3b MODELS ONLY Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the three bolts 1 the spark arrester 2 and the gasket 3 from the muffler 1 Bolts 2 Spark...

Page 133: ...k arrester and the gasket in the muffler and tighten the three bolts securely POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could ca...

Page 134: ...ance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner 1 Remove t...

Page 135: ...ne or low flash point solvents for cleaning ATV parts WHAT CAN HAPPEN A fire or explosion could result HOW TO AVOID THE HAZARD Use only a nonflammable or high flash point solvent to cleanATV parts 6 S...

Page 136: ...ding through water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the drain tube 1 Remove the drain tube 3...

Page 137: ...4 16 2 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the t...

Page 138: ...lock nut 3 and then turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of...

Page 139: ...3 FRONT BRAKE PADS The clearance between the brake pads and brake discs is adjusted automatically as the pads wear The only maintenance that is required is to replace brake pads when they become worn...

Page 140: ...aler to have brake pads replaced 3 Reinstall the wheel and tighten the lug nuts to 61N m 8 15 BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection windo...

Page 141: ...e and the brake pads are not worn beyond the recommended limit CH 8 14 there is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service To prevent damage...

Page 142: ...th engine temperature The coolant level should be between the maximum and minimum marks If the level is low remove the coolant reservoir cap and then add coolant or distilled water to raise it to the...

Page 143: ...imum level mark NOTE 1 If water is added have a KYMCO dealer check the antifreeze content of the coolant as soon as possible 2 The radiator fan operation is completely automatic It is switched on or o...

Page 144: ...teering recovers 2 Fuses in the harness may have blown There are several reasons that the fuses may blow Refer to the Fuse section in this chapter for details 3 Battery voltage has dropped Voltage dro...

Page 145: ...pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the...

Page 146: ...ts 8 19 2 INSTALLATION When reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Be sure the tapered side of the wheel nuts 1 face the wheel rim 2 Wheel Nut Torqu...

Page 147: ...direction of the wheel 1 Arrow mark Without arrow mark POTENTIAL HAZARD Installing wheels improperly WHAT CAN HAPPEN A wheel may come loose possibly leading to an accident HOW TO AVOID THE HAZARD Care...

Page 148: ...ery cells as this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care POTENTIAL HAZARD Allowing open flames or sparks near the ba...

Page 149: ...m the battery first and then disconnect the positive terminal lead 3 5 Remove the battery 8 20 2 Installation A Install in the reverse order of removal B After installing the battery check to see if t...

Page 150: ...tion switch is OFF To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Fuse box 2 Remove the front cover 3 Open the fuse box cap 4 Pull the old fuse out...

Page 151: ...r the seat 40A Fuse If the fuse is blown steering becomes heavy Replace the blown fuse with a fuse of the same specific amperage and type If a replaced fuse blows again there can be trouble with the E...

Page 152: ...the ignition switch at ON position Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting button 1 Adjusting button 8 23 DRIVE SHAFT BOOTS Check the protective boot...

Page 153: ...es can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate...

Page 154: ...alership have the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and...

Page 155: ...8 42 8 25 1 Troubleshooting chart...

Page 156: ...8 43 8 25 2 EPS EPS MODELS ONLY...

Page 157: ...you and others to operate A Before cleaning the ATV a Block the end of the exhaust pipe to prevent water entry Use a commercially available tapered rubber plug or a plastic bag with a strong rubber b...

Page 158: ...reaser off with a garden hose under normal pressure Use only enough water pressure to rinse the engine clean D Once the majority of the dirt has been rinsed off wash all of the surfaces with warm wate...

Page 159: ...axes as they may contain abrasives which may mar the paint or protective finish K When finished start the engine and allow it to idle for several minutes to evaporate any residual moisture POTENTIAL H...

Page 160: ...n the cover and then remove mud accumulated in the cover with water Where shall be careful Avoid spraying water in the electrical connectors Avoid spraying water with any great force near the followin...

Page 161: ...fuel tank and carburetor Be sure to drain the fuel in a well ventilated area not in a garage POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or i...

Page 162: ...ter for a few seconds to distribute the oil and then reinstall the spark plug 4 Remove the battery and store it in an area protected from freezing temperatures and direct sunlight and out of the reach...

Page 163: ...Overall Height 1250 mm 1340 mm Wheel Base 1297 mm 1297 mm Seat Height 880 mm 892 mm Minimum Ground Clearance 260 mm 272 mm Minimum Turning Radius 3450 mm 3450 mm Basic Weight With Oil and Full Fuel Ta...

Page 164: ...ABS Displacement 501 cc 695 cc Bore x stroke 92X75 4 mm 102X85 mm Compression ratio 10 7 1 10 3 1 Starting System Electric starter Lubrication System Wet sump Engine oil Transmission oil Rear final g...

Page 165: ...L 2 82 lmp qt 3 39 US qt 2 6 L 2 29 lmp qt 2 76 US qt Total Amount 3 6 L 3 17 lmp qt 3 82 US qt 2 9 L 2 64 Imp qt 3 07 US qt Front Gear Case Oil Quantity Front Gear box oil classification SAE 90 Peri...

Page 166: ...filter Air filter element Oil coated paper element Fuel Type Unleaded fuel Tank capacity 21 L 4 62 lmp gal 5 55 US gal Reserve amount 5 L 1 1 lmp gal 1 32 US gal Fuel injection Type Throttle body Spa...

Page 167: ...spension Front Dual A arm Rear Dual A arm Shock absorber Front Coil spring Oil damper Rear Coil spring Oil damper Electrical Ignition system ECU automatic control Generator system Battery type A C mag...

Page 168: ...5 0 psi 0 38 kgf cm2 5 5 psi Rear tire pressure 0 32 kgf cm2 4 7 psi 0 35 kgf cm2 5 0 psi Bulb voltage wattage quantity Headlight 12V 35W 35W X2 Brake light 12V 21W X2 Taillight 12V 5W X2 Turn signal...

Page 169: ...evice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle...

Page 170: ...done in accordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENACE INTERVAL DATE...

Page 171: ...g Taiwan Republic of China Telephone 886 7 3822526 FAX 886 7 3950021 By KWANG YANG Motor Co Ltd Third Edition Sep 2021 All rights reserved Any reproduction or unauthorized use without the written perm...

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